Olefin Resin Packaging Structure for Oxygen Barrier Without Foaming
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Solution Overview
Problem
Olefin-based resin packaging materials face challenges in achieving oxygen barrier properties while maintaining recyclability due to foaming issues when combined with ethylene-vinyl alcohol copolymer (EVOH) and iron powder, which are not adequately addressed in existing technologies.
Innovation Solution
A packaging material with a multilayered structure containing an olefin-based resin, a regrind layer with a controlled amount of iron powder and EVOH, and a gas barrier resin, ensuring a mass ratio of iron powder to EVOH of 1.0 or less, to suppress foaming and maintain oxygen barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multilayered structure including EVOH and iron powder is used to improve oxygen barrier properties, then oxygen barrier properties are improved, but foaming occurs in the regrind layer causing appearance defects and decreased oxygen barrier properties
Solution Approach 1:
The patent extracts the harmful interaction between iron powder and EVOH by separating their functions. Instead of mixing them in the same layer, the invention uses iron powder as an oxygen absorbent in one layer and EVOH as an oxygen barrier resin in another layer, preventing the foaming reaction while maintaining both oxygen barrier properties and oxygen absorption capability.
Solution Approach 2:
The packaging material is divided into multiple functional layers with distinct compositions. The oxygen absorbent layer containing iron powder is separated from the oxygen barrier layer containing EVOH, and a regrind layer is positioned between them to prevent interaction. This segmentation eliminates the foaming problem while preserving the benefits of both materials.
2Reliability
If different kinds of materials are used to impart oxygen barrier properties, then oxygen barrier properties are improved, but recyclability and mono-materialization are compromised
Solution Approach 1:
The patent creates a multilayer composite structure where each layer serves a specific function. The combination of olefin-based resin, EVOH, and iron powder in separate layers provides both oxygen barrier properties and recyclability. The structured composite allows for selective material recovery and reuse while maintaining performance requirements.
3Reliability
If iron powder is used as oxygen absorbent to improve oxygen barrier properties, then oxygen barrier properties are improved, but foaming occurs when combined with EVOH in regrind layer
Solution Approach 1:
The patent introduces an intermediary regrind layer positioned between the oxygen absorbent layer containing iron powder and the oxygen barrier layer containing EVOH. This intermediary layer acts as a barrier preventing direct contact and chemical interaction between iron powder and EVOH, thereby eliminating the foaming problem while allowing both layers to function effectively.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents foaming and maintains excellent oxygen barrier properties, enabling recyclability and mono-materialization of the packaging material, while using a small amount of iron powder for environmental sustainability.
Implementation Method 1
a container having a multilayered structure including an oxygen absorbing layer of an oxygen absorbent (or deoxidizer) containing an iron powder has attracted attention. This is because the iron powder is an inorganic material, and thus can be easily separated from the resin
Implementation Method 2
a multilayered structure including an oxygen barrier resin exhibiting always constant oxygen barrier properties, called passive barrier properties
Data Source
AI summary
An olefin-based resin packaging material containing a large amount of an olefin-based resin, suitable in recyclability of the olefin-based resin, and having excellent characteristics not found in the olefin-based resin. The olefin-based resin packaging material contains, per 100 parts by mass of the packaging material, an olefin-based resin in an amount of 80 parts by mass or more; a resin other than the olefin-based resin in an amount suppressed to less than 16.9 parts by mass; and an iron powder in an amount of less than 5 parts by mass.